इ टरन ट म नक Disclosure to Promote the Right To Information Whereas the Parliament of India has set out to provide a practical regime of right to information for citizens to secure access to information under the control of public authorities, in order to promote transparency and accountability in the working of every public authority, and whereas the attached publication of the Bureau of Indian Standards is of particular interest to the public, particularly disadvantaged communities and those engaged in the pursuit of education and knowledge, the attached public safety standard is made available to promote the timely dissemination of this information in an accurate manner to the public. ज न1 क अ+धक र, ज 1 क अ+धक र Mazdoor Kisan Shakti Sangathan The Right to Information, The Right to Live प0र 1 क छ ड न' 5 तरफ Jawaharlal Nehru Step Out From the Old to the New IS 9282 (2002): Wire Ropes and Strands for Suspension Bridges [MED 10: Mechanical Engineering]! न $ एक न' भ रत क +नम-ण Satyanarayan Gangaram Pitroda Invent a New India Using Knowledge! न एक ऐस खज न > ज कभ च0र य नहB ज सकत ह ह Bhartṛhari Nītiśatakam Knowledge is such a treasure which cannot be stolen
(Reaffirmed 2008) Indian Standard WIRE ROPES AND STRANDS FOR SUSPENSION BRIDGES SPECIFICATION ( First Revision ) ICS 77 140 65 93 040 BIS 2002 BUREAU O F I N D I A N S T A N D A R D S MANAK BHAVAN, 9 BAHADUR SHAH ZAFAR MARG NEW DELHI 110002 August 2002 Price Group 5
Wire Ropes and Wire Products Sectional Committee, ME 10 FOREWORD This Indian Standard ( First Revision ) was adopted by the Bureau of Indian Standards, after the draft finalized by the Wire Ropes and Wire Products Sectional Committee had been approved by the Mechanical Engineering Division Council This standard was first published in 1979 This standard was prepared since the absence of such a standard was long felt by designers and engineers for erection of suspension bridges either for pedestrian, vehicular or other use the wire ropes and strands covered in the standard are suitable for stiffened as well as unstiffened suspension bridges This standard was prepared in consultation with the leading manufacturers and important users In this first revision, based on the experience gained in the industry, construction details, modulus of elasticily and certain other requirements have been modified Requirement of lubrication is also added The composition of the Committee responsible for the formulation of this standard is given in Annex B For the purpose of deciding whether.a particular requirement of this standard is complied with the final value observed or calculated, expressing the result of a test or analysis, shall be rounded off in accordance with IS 2 1960 'Rules for rounding off numerical values ( revised )' The number of significant places retained in the rounded off value should be the same as that of the specified value in this standard
AMENDMENT NO. 1 AUGUST 2004 TO WIRE ROPES AND STRANDS FOR SUSPENSION BRIDGES SPECIFICATION ( First Revision ) ( Page, 2 clause 11 ) Substitute the following for the existing text under the captions of clause 11 'In case of pre-stretched wire ropes, Annex A given for guidance may be referred ' ( Page 9, Table 12, last column ) Substitute the wording 'Pre-stretched' for 'Pre-stressed' ( ME 10 ) Reprography Unit, BIS. New Delhi, India
Indian Standard WIRE ROPES AND STRANDS FOR SUSPENSION BRIDGES SPECIFICATION ( First Revision ) 1 SCOPE This standard covers requirements For wire ropes and strands for use in suspension bridges for pedestrian, vehicular traffic pipe crossing and other applications The following types, constructions, rope/strand grades and size ranges are covered ( identified by mark ) 3 TERMINOLOGY For the purpose of this standard, the terms and definitions given in IS 2363 shall apply 4 MATERIAL 4.1 All the wires used in the manufacture of ropes Type Constraction Rope/Strand Grade Core Size Range Table No Round Strand Spiral Strand Half and Full Locked Coil Wire Rope a) b) c) a) b) c) d) e) f) g) h) 7 7(6-1) 7 19 M (12/6-1) 7 37 M (18/12/6-1) 1 7(6-1) 1 I9 J(126-1) 1 37 J (18 126-1) 1 61 J(24 18 12 6-1) 1 91 J(30 24 1812 6-1) 1 9I J (30 24 18.12-6F-6-1) 1 127 J(36 30 24 18 12 6-1) 1 169 J(42 36 30 24 18 12 6-1) 1 420 1 370 1 470 1 570 12-32 23-48 38-64 6-15 12-25 20-35 26-45 33-56 33-56 40-65 40-65 26-80 26-80 1 2 3 4 5 6 7 8 8 9 10 11 11 2 REFERENCES The following Indian Standards contain provisions, which through reference in this text constitute provision of this standard At the time of publication, the editions indicated were valid. All standards are subject to revision, and parties to agreements based on this standard are encouraged to investigate the possibility of applying the most recent editions of the standards indicated below IS No Tula 1608-1995 Mechanical testing of metals Tensile testing ( second revision ) 1835 1976 Round steel wire for ropes ( third revision ) 2363 1981 Glossary of terms relating to wire ropes ( first revision ) 6594 2001 Technical supply conditions for steel wire ropes ( second revision ) 1 and strands shall comply with the requirements laid down in IS 1835 In case of locked coil wire ropes, the shaped wires shall conform to the requirements of dimension and tensile test only 4.2 Requirements of Wire 4.2.1 Dimensional Limits and Tolerances The wire size tolerance shall be in accordance with IS 1835 as applicable for galvanized wire 'Type A' The dimensions of shaped wires in case of locked coil wire ropes shall be provided at the discretion of the manufacturer. 4.2.2 Tensile Test For stranded rope and spiral strand the tensile designation of individual wires shall be chosen as recommended in IS 6594 In case of locked coil wire ropes use of wires of different tensile designations is permitted but the combined tensile strength shall not
fall below 1 370 or 1 470 as applicable shown in the Table 11 Manufacturer shall provide tensile designation of all wires used in the locked coil wire ropes NOTE. In general thc shaped Wires shall be of lower tensile designation whereas the round wires shall be of higher tensile designation 4.2.3 The tensile strength shall be checked in accordance with IS 1608 and shall meet the requirement of IS 1835 4.3 Elongation Test The wire shall have an elongation not less than 4 percent of a gauge length equivalent to '100 diameter of wire'. 4.4 Proof Stress When subjected to 0 2 percent proof stress test the wire shall show a force equivalent to atleast 70 percent of the breaking force of the wire 4.5 Galvanizing 4.5.1 All wires shall be galvanized The galvanizing shall be carried out either by the hot dip or electrical process to provide a continuous, uniform coating of zinc of purity not less than 98 percent The zinc coating shall be of 'Type A' according to IS 1835 for round wires For shaped wires the mass of zinc coating shall not be less than 45 g/m 2 4.5.2 Wrap Test The wire shall not show any fracture when wrapped at a rate not exceeding 15 turns per minute in a close helix for at least 2 turns around a cylmdrical mandrel 4 times in diameter of the wire to be tested for wires of tensile strength 1570 N/mm 2 and 3 times the diameter of the wire to be tested in case of lower tensile strength. 5 GENERAL REQUIREMENTS General requirements shall be according to IS 6594 6 JOINTS 6.1 In case of stranded and locked coil ropes, joint in wires shall be avoided as far as possible except where they are necessitated by the length of the rope The joints in the wires of the strand shall be distributed as widely as possible and in no case shall more than one wire be joined in any length of 10 m of strand in case of a stranded rope and 10 m of rope length in case of locked coil wire ropes 6.2 Joints shall be either brazed or electrically welded If joints are brazed they shall be properly scarfed or if welded properly annealed. Tucked joints shall not be used 7 DIRECTION OF LAY 7.1 Unless otherwise stated, the locked coil wire ropes and spiral strands shall be of right hand lay (z), and round strand wire ropes shall be of right hand ordinary lay ( sz ) 7.2 Stranded rapes shall be of ordinary lay (.sz or zs ) 7.3 Spiral strands and locked coil ropes shall be so constructed that the wires in successive layers are alternatively laid However, in case of locked coil wire ropes, the outer layers may be laid in one direction and all the inner layers in the opposite direction 8 LENGTH OF LAY 8.1 The length of lay for stranded ropes shall not exceed 8 times the nominal diameter of the rope 8.2 The length of lay for spiral strands shall not exceed 15 times the nominal diameter of the strand 8.3 The length of lay for locked coil wire ropes shall not exceed 15 times the nominal diameter of the locked coil wire rope. 9 LUBRICATION The wire ropes/strands and the locked coil wire ropes shall be lubricated or not lubricated as per the requirement of the purchaser 10 MINIMUM BREAKING FORCE The minimum breaking force of wire ropes shall be as given in Tables 1 to 11 11 ELONGATION OR STRETCH OF WIRE ROPE For elongation or stretch of wire ropes, see Annex A 12 MARKING 12.1 The size, construction, rope grade, lay, core. coating and length of wire rope, reel coil number along with the order number of purchaser and any other marking which may be specified by the purchaser shall be legibly mentioned on a suitable tag securely attached, when wire ropes are supplied in coils In case wire ropes are supplied in reels, the information may be stenciled on both sides of the reels or stenciled on one side of the reel and a suitable tag giving the same information may be attached on the other side of the reel 12.2 BIS Certification Marking 12.2.1 The product may be marked with the Standard Mark 12.2.2 The use of the Standard Mark is governed by
the provisions of Bureau of Indian Standards Act, 1986 and the Rules and Regulations made thereunder The details of conditions under which a licence for the use of Standard Mark may be granted to the manufacturers or producers may be obtained from the Bureau of Indian Standards 13 PACKING The rope shall be suitably protected to avoid damage in transit and corrosion Ropes of ordinary lay may be supplied in coils or reels as required by the purchaser NOTE Lang's lay ropes and multi strand rotation-resistant rope should preferably be supplied on reels unless specified otherwise Table 1 Round Strand 7 7 ( 6-1 ) Construction Wire Rope Table 2 Round Strand 7 19 M ( 12/6-1 ) Construction Wire Rope 12 13 14 15 k g / 100 m 566 664 770 884 Minimum Breaking Force Corresponding to the Rope Grade of 1 420 7 1 8 6 100 1 15 1 570 ( 4 ) 81 9 5 110 127-1 % 2 3 2 4 2 5 2 6 2 7 k g / 100 m 201 219 238 257 277 Minimum Breaking Force Corresponding to the Rope Grade of 1 420 249 271 295 319 344 1570 ( 4 ) 276 300 326 352 380 16 101 130 144 2 8 298 369 409 17 18 114 127 147 165 163 183 29 3 0 320 343 396 424 498 469 19 142 184 203 3 1 366 453 501 2 0 21 157 173 204 225 225 248 3 2 33 390 414 483 5I3 534 567 22 190 247 273 3 4 440 545 602 23 208 270 298 3 5 466 577 638 2 4 25 226 246 293 318 324 352 3 6 3 7 493 521 611 645 675 713 2 6 266 344 381 3 8 550 681 752 2 7 287 371 411 3 9 579 717 793 2 8 308 399 442 4 0 609 754 834 2 9 331 428 474 4 1 640 792 876 3 0 354 459 507 4 2 671 831 919 31 3 2 378 403 490 522 1 To calculate culculalt the aggregate breaking force multiply the values given in in columns 3 and 4 bv 1 194 2 The values tor masses are for guidance only 541 577 4 3 4 4 4 5 4 6 4 7 4 8 704 737 771 805 841 877 871 912 954 997 1041 1086 963 1009 1055 1103 1151 1201 values given in columns 3 and 4 by 125 3
Table 3 Round Strand 7 37 M ( 18/12/6-1 ) Construction Wire Rope Table 4 Spiral Strand 1 7 ( 6-1 ) Construction Wire Rope k g / 100 m Minimum Breaking Force Corresponding to the Rope Grade of 1 420 1 570-1 % kg / 100m Minimum Breaking Force Corresponding to the Strand Grade of 1 420 1 5 7 0 ( 4 ) ( 4 ) 38 550 653 722 6 181 2 8 31 3 9 4 0 41 4 2 43 4 4 4 5 4 6 4 7 579 609 640 671 704 737 77! 805 841 688 723 760 798 836 875 916 957 999 760 800 840 882 924 968 1012 1058 1104 7 8 9 10 11 12 13 14 15 246 321 407 502 607 723 848 984 113 3 8 4 9 6 3 7 7 9 4 111 131 151 174 4 2 55 6 9 85 103 123 144 167 192 48 877 1042 1152 49 50 51 914 952 990 1086 1430 1176 1200 1250 1300 values given in columns 3 and 4 by 1111 52 1029 1223 1352 53 1069 1270 1404 54 1410 1318 1458 55 1151 1368 1512 5 6 1194 1418 1568 5 7 1237 1 469 1624 58 1280 1521 1682 5 9 1325 1574 1740 6 0 1370 1628 1800 6 1 1416 1682 1860 6 2 I463 1738 1922 6 3 1511 1794 1984 6 4 1559 1852 2048 values given in columns 3 and 4 by 1302 2 the values for masses are for guidance only 4
Table 5 Spiral Strand 1 19 J ( 12 : 6-1 ) Construction Table 6 Spiral Strand 1 37 J ( 18 : 12 : 6-1 ) Construction 12 13 14 15 16 17 18 19 20 21 22 23 24 25 MASS kg / 100 m 71 84 97 111 127 143 161 179 198 218 240 262 285 310 Minimum Breaking Force Corresponding to the Strand Grade of I 420 107 126 146 168 191 216 242 269 298 329 361 395 430 466 1 570 ( 4 ) 119 139 162 186 211 238 267 298 330 364 399 436 475 515 values given in columns 3 and 4 by 1 136 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 kg / 100 m 196 216 237 259 282 306 330 356 383 411 440 470 501 532 565 599 Minimum Breaking Force Corresponding to the Strand Grade of 1 420 294 325 356 389 424 460 498 537 577 619 663 707 754 802 851 902 1 570 ( 4 ) 326 359 394 431 469 509 550 593 638 684 732 782 833 886 941 997 values given in columns 3 and 4 by 1 136 5
Table 7 Spiral Strand 1 61 J ( 24:18:12:6-1 ) Construction Table 8 Sprial Strand 1 91 J ( 30:24:18:12:6-1 ) ( 30:24:18:12-6F-6-l ) Construction 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 kg / 100 m 327 352 379 406 435 464 495 526 558 592 626 661 697 735 773 812 852 893 935 978 Minimum Breaking Force Corresponding to the Strand Grade of 1 570 544 586 630 676 724 773 823 876 929 985 1042 1101 1161 1223 1286 1352 1418 1487 1557 1628 values given in column 3 by 1 136 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 kg / 100 m 525 557 590 624 659 696 733 771 810 850 891 933 975 1019 1064 1110 1157 1204 1253 1303 1353 1405 1457 56 1511 Minimum Breaking Force Corresponding to the Strand Grade of 1 570 873 927 982 1034 1098 1158 1220 1283 1348 1415 1483 1553 1624 1697 1772 1848 1925 2005 2086 2168 2253 2339 2426 2515 values given in column 3 by 1 136 6
Table 9 Sprial Strand 1 127 J ( 36:30:24:18:12:6-1 ) Construction Table 10 Sprial Strand 1 169 J ( 42:36:30:24:18:12:6-1 ) Construction 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 kg / 100m 771 810 850 891 933 975 1019 1064 1110 1157 1204 1253 1303 1353 1405 1457 1511 1565 1620 1677 1734 1792 1852 1912 1973 2035 Minimum Breaking Force Corresponding to the Rope Grade of 1 57 0 1283 1348 1415 1483 1553 1624 1697 1772 1848 1925 2005 2086 2168 2253 2339 2426 2515 2606 2698 2792 2887 2984 3083 3183 3285 3388 values given in column 3 by 1 136 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 kg / 100 m 771 810 850 891 933 975 I019 1064 1110 1157 1204 1253 1303 1353 1405 1457 1511 1565 1620 1677 1734 1792 1852 1912 1973 2035 Minimum Breaking Force Corresponding to the Rope Grade of 1 570 1283 1348 1415 1483 1553 1624 1697 1772 1848 1925 2005 2086 2168 2253 2339 2426 2515 2606 2698 2792 2887 2384 3083 3183 3285 3388 values given in column 3 by 1 136 7
Table 11 Halfand Full Locked Coil Wire Rope (Clauses 1 and 10) rope dia = d factor (K) = 0 562 5 Rope mass (kg/100 m) = Kd 2 Breaking force factor Minimum breaking force of Minimum Breaking Force of the Locked Coil Wire Rope (d) Corresponding to the Rope Grade of (kg / 100 m) 1 370 1 470 ( 4 ) 26 28 30 32 34 36 38 40 42 43 44 46 48 50 51 52 53 54 56 58 60 62 64 66 68 70 72 74 76 78 80 380 441 506 576 650 729 812 990 992 1 O40 1 089 1 190 1 296 1 406 ] 463 1 521 1 580 1 640 1 764 1 892 2 025 2 162 2 304 2 450 2 601 2 756 2916 3 080 3 249 3 422 3 600 518 601 690 785 886 993 1107 1226 1352 1417 1484 1622 1766 1916 1993 2072 2153 2235 2403 2578 2759 2946 3139 3338 3544 3755 3973 4197 4427 4663 4905 values given in columns 3 and 4 by 1 09 556 645 740 842 951 1066 1187 1316 1451 1520 1592 1740 1895 2056 2139 2224 2310 2198 2579 2766 2960 3161 3368 3582 3802 4029 4263 4503 4750 5003 5263 8
ANNE A (Clause 11) ELONGATION OR STRETCH OF WIRE ROPE/STRAND A-1 STRECHES IN WIRE ROPE STRANDS There are two kinds of stretches in a wire rope/strand A-1.1 Permanent Constructional Stretch This is caused by the lengthening of the rope/strand lay and the reduction in rope/strand diameter The extent of this stretch depends upon the rope /strand construction, the length of lay, the type of core and some other factors. For stranded operating ropes, this stretch varies from 0 25 percent to 1 0 percent depending upon the operating loads. For locked coil wire ropes and spiral strands the comparable figure of permanent constructional stretch would be from 0 15 percent to 0 5 percent A-1.2 Elastic Stretch This is caused by the action of tensile stress on the metallic area of the rope/strand conforming to their elastic property The amount of elastic stretch may be determined by the formula given below where l e = elastic stretch of rope/strand in cm, P = load or tension on rope/strand in N, L = initial length of rope/strand under stress in cm, A = metallic area of rope/strand in cm 2 ; and E, = modulus of elasticity of rope/strand in N/cm 2 based on its metallic area. A-2 MODULUS OF ELASTICITY Commonly used approximate value of modulus of elasticity for various constructions of wire ropes/ strands covered under this specification are given in Table 12 New or unused ropes/strands invariably have a total elongation under load greater than used rope/ strands of the same specification, since the larger pan of the stretch occurs during the initial period of its useful life. Subsequently, the modulus of elasticity would also be smallest for a wire rope/strand during this period Modulus of elasticity for old and used rope/ strand is approximately 20 percent in excess of values shown in Table 12 It is for this reason that pre-stressed ropes/strands are preferred for construction of bridges. Pre-stressing is the process of cyclic loading of the rope/strand to 5 to 50 percent of the minimum breaking strength till the stretch in the rope/strand at any given load between 5 percent and 50 percent stabilizes. Table 12 indicates the comparative values prior to pre-stressing and after pre-stressing. SI No. 1 2 3 Table 12 Modulus of Elasticity of Rope/Strand Type of Wire Rope/Strand Stranded rope Spiral strand Full locked and half locked toil wire rope Construction 7 7 7 19 7 37 1 7 I 19 1 37 1 61 I 91 1 127 Modulus of Elasticity in N/c As Manufactured 6 9 10 6 6 5 10 6 6 1 10 6 11 0 10 6 100 10 6 9 5 10 6 9 3 10 6 9 0 10 6 8 7 10 6 103 10 6 m 2 Pre-s tressed 8 6 10 6 8 1 10 6 7 6 10 6 13 1 10 6 12 8 10 6 12 8 10 6 120 10 6 117 10 6 113 10 6 13 1 10 6 9
I S 9282 : 2002 Organization Directorate General of Mines Safety, Dhanbad Aerial Ropeway & Mechanical Handling Co Pvt Ltd, Kolkata Amar Promoters Pvt Ltd, Solan Bharat Coking Coal Ltd, Dhanbad Bharat Wire Ropes Ltd, Mumbai C entral Mining Research Institute, Dhanhad ANNE B (Foreword) COMMITTEE COMPOSITION Wire Ropes and Wire Products Sectional Committee, ME 10 Directorate General of Aeronautical Quality Assurance, New Delhi Directorate General of Civil Aviation, New Delhi Eastern Coalfields. Ltd kolkata For William Industries Ltd, Hooghly JC I Ltd ( Division), Hoshiarpur Ministry of Defence (Naval). New Delhi Ministry of Surface Transport, New Delhi National Test House, Ghaziabad North basten Coalfields Lid, Kolkata Oil and Natural Gas Commission. Dehra Dun Research Designs & Standards Organization, Lucknow South Eastern Coalfields Ltd, Belaspur Usha Breco Ltd, Kolkata Usha Martin Induslns Lid, Ranchi Vidarhha Hardware Industnes. Akola BIS Directorate General Member-Secretary SHRI P VENKATESWARA RAO Joint Director (MED), BIS Representative (s) SHRI D S AHA (Chairman) SHRI S P BANSAI (Alternate) SHRI A K KINRA SHRI RANJAN MUKHERJEE (Alternate) SHRI VIRENDER AGARWAL SHRI JATINDER AGARWAL (Alternate) SHRI R k PRASAD SHRI D M SHAH SHRI S P CHAUDHARY SHRI R P CHARABORTY(Alternate) SHRI S H PRASAD SHRI SANJAY CHAWLA (Alternate) SHRI R C GUPTA SHRI M M KAUSHAI (Alternate) SHRI k CHARABORTY SHRI J L RAIHI SHRI B A S U D E B BANERJEE (Alternate) SHRI S K SETHI SHRI M l SHARMA ( Alternate) C DR BRAHAMSWAROOP SHRI B L??? (Alternate) SHRI G P ROY SHRI T K DEHTA(Alternate) SHRI D S MAJUMDAR SHRI B N SARKAR (Alternate) SHRI A TIRKEY SHRI R K GARG SHRI P K SOOD (Alternate) DEPUTY DIRECTOR (Standards) SHRI S k MISHRA SHRI G RAMASWMAMI (Alternate) SHRI AMIT KUMAR BASU SHRI C K KARMAKAR (Alternate) SHRI RANA PRATAP SHRI K K SENGUPTA (Alternate) SHRI O P DALMIA SHRI SANJAY K DALMIA (Alternate) SHRI M L CHOPRA, Director & Head (MED) [Representing Director General (Ex-offico)] 10
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